Engineering Commons^™

Upcyclying Of Polyethylene Terephtalate By Addition Of Thermoplastic Elastomer, Diego Francisco Bermudez

Open Access Theses & Dissertations

Continual overconsumption of single-use plastics has generated challenges of solid waste management across the United States. Common plastic waste management solutions, such as landfill, have caused the migration of contaminants into the environment consequently affecting not only the health of wildlife, but also that of human beings. Alternative strategies for the handling of single-use plastic such as polyethylene terephthalate (PET), used in the food packaging industry, can ultimately help mitigate the noxious consequences of single-use plastics affecting entire ecosystems. This study demonstrates a potential avenue of materials upcycling by studying the effects of coupling PET with the thermoplastic elastomer styrene-ethylene-butylene-styrene …

Ultrasonic Non-Destructive Evaluation Of Additively Manufactured Polymer-Ceramic Composites, Christian Alexander Ruiz

Open Access Theses & Dissertations

Digital light processing (DLP) is an attractive additive manufacturing technique due to its ability to create ceramic parts with complex geometries. DLP uses ultraviolet light to polymerize a slurry comprised of ceramic powder and photosensitive resin in layers to create solid parts. Printing parameters such as light intensity and exposure time are critical when producing these parts. Improper parameters can lead to over or under-curing, adversely impacting print quality and strength. Samples were printed at varying layer exposure times and then tested using ultrasonics to determine the degree of conversion. Additionally, ultrasonics were used as a non-destructive technique to obtain …

Characterization Of Aerosol Jet Printed Silver Thin Films Sintered By A Scanning Laser, William A. Metzger

Browse all Theses and Dissertations

Direct write printing, which is part of additive manufacturing (AM) technology, offers unique capabilities that can complement traditional methods of electronics fabrication. Printing of electrical interconnects via aerosolization is one of the areas in AM that is very important in electronics fabrication. Post-print sintering is a critical step in printed electrical interconnects because it strongly influences the electrical resistivity of the interconnects. Interconnects require the lowest possible resistivity to achieve better performance. Thermal sintering is the most common technique employed in printed interconnects. However, it is limited to substrates that can handle the high temperature requirement for sintering. For polymers …

Direct Ink Write Processing Of Signal Crossovers Using Aerosol Jet Printing Method, Lucas A. Clark

Browse all Theses and Dissertations

Electronics in different applications, such as in medical imaging devices, radar systems, communication transmitters, and optical drives, often require various power and signal lines to be integrated at board level. In such cases, different lines may cross over one another in three-dimensional space for efficient electronic integration. Crossovers are usually achieved by adding additional layers to a PCB. However, these additional layers increase the cost, weight, and complexity of the component. By creating a process and structure to offer board-level heterogenous integration, these factors may be reduced. RF-DC crossovers were designed and additively manufactured using an aerosol jet printer. Benzocyclobutene …

Additive Manufacturing Of Aluminum Alloy By Metal Fused Filament Fabrication (Mf3)., Luke J. Malone

Electronic Theses and Dissertations

This research studies metal-fused filament fabrication (MF3) for manufacturing aluminum alloy parts. An aluminum alloy powder-based feedstock with a polymer-binder system was extruded via capillary rheometry to form a filament. The filament was used to print green parts that were involved in a two-step debinding process combining solvent and thermal extraction of the polymer binder, then sintered in a partial vacuum. Resulting grain structure, sintered density, and mechanical properties will be characterized and compared to metal injection molded (MIM) specimens. The main objective is to gain an understanding of the MF3 process characteristics and the ensuing material properties and microstructure …

Additive Manufacturing Of Variable Contrast Computed Tomography Anatomical Phantoms Using A Single Feedstock In Fused Filament Fabrication, Cory J. Darling

University of New Orleans Theses and Dissertations

Anatomical phantoms used in biomedical education and training benefit greatly from Fused filament fabrication’s (FFF) ability to rapidly produce complex and unique models. Current materials and methods used in FFF have limited ability to accurately produce phantoms that can mimic the radiological properties of multiple biological tissues. This research demonstrates that the CT contrast of FFF produced models can be modified by varying the concentration of bismuth oxide in acrylonitrile butadiene styrene (ABS) filaments and a tunable CT contrast that mimics the CT contrast ranging from fatty tissue to cortical bone using a single composite filament without introducing artificial image …

Design And Testing Of A Composite Compressor Rotor, Mauro Noel V. De Leon

Theses and Dissertations

Additive manufacturing (AM) and molding are manufacturing methods known for building representations or replicas of conceptualized engine components, but was considered impractical for manufacturing operating engine components. More recent technology has rendered composite materials (combining high-temperature polymers and fiber reinforcement) capable of withstanding the temperature and structural requirements to compete with conventional turbomachinery metals. This study explores the application of several high-temperature polymers (ULTEM 9085, Onyx-Carbon fiber, and Epoxy-Carbon fiber) and their survivability in the operating conditions of a P400 Engine compressor. The tests conducted for this study determined their viability as compressor materials. This study required conducting tensile specimen …

Structural Stability Of Thermosets During Material Extrusion Additive Manufacturing, Stian K. Romberg

Doctoral Dissertations

Over the past decade, the scale of polymer additive manufacturing has been revolutionized with machines that print massive thermoplastic parts with greater geometric complexity than can be achieved by traditional manufacturing methods. However, the heat required to print thermoplastics consumes energy and induces thermal gradients that can reduce manufacturing flexibility and final mechanical properties. With the ability to be extruded at room temperature and excellent compatibility with fibers and fillers, thermoset resins show promise to decrease the energy consumption, expand the manufacturing flexibility, and broaden the material palette offered by large-scale polymer additive manufacturing. However, structural instability in the uncured …

3d Printed Concrete & Polymer Concrete For Infrastructure Applications, Daniel Heras Murcia

Civil Engineering ETDs

Additive manufacturing technology has been established as one of the fastest-growing building technologies worldwide. Three-dimensional concrete printing (3DCP) has developed an increasing interest in the last decade due to its prospects as a transformative technology for industries such as the concrete precast. Besides the improvements in automation technologies in construction, traditional construction has faced considerable challenges: high accident rates, labor dependency, significant potential for automation, and high costs associated with the use of traditional formwork. In this context, three-dimensional concrete, also referred to as physical prototyping, is a novel construction technique in which the concrete is extruded layer-to-layer. 3DCP is …

Evaluation Of Additively Manufactured Lattices Under High Strain Rate Impact, Derek G. Spear

Theses and Dissertations

Several additively manufactured lattice designs and configurations were evaluated under compression loads under various strain rates from quasi-static to highly dynamic. These experiments examined how the mechanical behavior of the lattice changed based on the lattice design properties and the applied strain rates. The modulus of elasticity, yield strength, plateau stress, and toughness were observed to decrease with an increase in strain rate, revealing that the lattice designs exhibit a negative strain rate sensitivity. A new lattice flow stress model was developed to account for the mechanical response of the lattice and was incorporated into a computational model for simulation. …

Process-Structure-Property Relationships In 3d-Printed Epoxy Composites Produced Via Material Extrusion Additive Manufacturing, Nadim S. Hmeidat

Doctoral Dissertations

Extrusion-based additive manufacturing (AM) technologies, such as direct ink writing (DIW), offer unique opportunities to create composite materials and novel multi-material architectures that are not feasible using other AM technologies. DIW is a novel 3D-printing approach in which viscoelastic inks, with favorable rheological properties, are extruded through fine nozzles and patterned in a filament form at room temperature.

Recent developments in DIW of polymer composites have led to expanding the range of materials used for printing, as well as introducing novel deposition strategies to control filler orientation and create improved functional/structural composite materials. Despite these substantial advancements, the successful and …

Quality Assurance Of Lightweight Structures Via Phase-Based Motion Estimation, Ikenna E. Ifekaonwu

Electronic Theses and Dissertations

In recent years, lightweight structures have become mature and adopted in various applications. The importance of quality assurance cannot be overemphasized hence extensive research has been conducted to assess the quality of lightweight structures. This study investigates a novel process that exploits motion magnification to investigate the damage characteristics of lightweight mission-critical parts. The goal is to assure the structural integrity of 3D printed structures and composite structures by determining the inherent defects present in the part by exploiting their vibration characteristics. The minuscule vibration of the structure was recorded with the aid of a high-speed digital camera, and the …

Structural Dynamic And Inherent Damping Characterization Of Additively Manufactured Airfoil Components, Andrew W. Goldin

Theses and Dissertations

The push for low cost and higher performance/efficient turbine engines have introduced a new demand for novel technologies to improve robustness to vibrations resulting in High Cycle Fatigue (HCF). There have been many proposed solutions to this, some passive and some active. With the advent of Additive Manufacturing (AM), new damping techniques can now be incorporated directly into the design and manufacture process to suppress the vibrations that create HCF. In this study, this novel unfused pocket damping technology is applied to a blade structure and the resulting damping effectiveness is quantified. The application of this technology to complex geometries …

Modeling And Validations Of Control Parameters For Material Extrusion-Based Additive Manufacturing Of Thixotropic Aluminum Alloys., Lars Herhold

Electronic Theses and Dissertations

Additive Manufacturing (AM) with metals has been accomplished mainly through powder bed fusion processes. Initial experiments and simulations using Material Extrusion Additive Manufacturing (MEAM) have been performed by various researchers especially using low melting alloys. Recently Stratasys Inc. submitted a patent application for the use of their Material Extrusion technology also called Fused Deposition Modeling (FDM) where they describe the process using thixotropic semi-solid alloys. Currently this process using semi-solid, engineering type alloys such as A356 or THIXALLOY 540 aluminum have not been researched to evaluate the control parameters. This research combines the in-depth knowledge of applying thixotropic semi-solid aluminum …

Ultrasonic Nondestructive Evaluation Of Metal Additive Manufacturing., Venkata Karthik Nadimpalli

Electronic Theses and Dissertations

Metal Additive Manufacturing (AM) is increasingly being used to make functional components. One of the barriers for AM components to become mainstream is the difficulty to certify them. AM components can have widely different properties based on process parameters. Improving an AM processes requires an understanding of process-structure-property correlations, which can be gathered in-situ and post-process through nondestructive and destructive methods. In this study, two metal AM processes were studied, the first is Ultrasonic Additive Manufacturing (UAM) and the second is Laser Powder Bed Fusion (L-PBF). The typical problems with UAM components are inter-layer and inter-track defects. To improve the …

Development And Characterization Of Novel Materials For The Advancement Of Additive Manufacturing By Material Extrusion 3d Printing, Jose Gilberto Siqueiros

Open Access Theses & Dissertations

The development of additive manufacturing technologies has been under the spotlight from the past decade due to its enormous potential to disrupt current manufacturing processes. Material extrusion 3D printing (ME3DP) is the most common type of additive manufacturing technology as it experienced an exponential growth after the expiration of the fused deposition modeling patent filed in 1989 by Scott Crump. The large interest behind this technology is generated from the capacity to create complex shapes, rapid prototyping, relatively ease of use, low cost, and high accessibility. The gradual evolution of material extrusion 3D printing calls to become a technology ordinarily …

3d Printing Of 316l Stainless Steel And Its Effect On Microstructure And Mechanical Properties, Rawn Penn

Graduate Theses & Non-Theses

Laser powder bed fusion or 3D printing is a potential candidate for net shape forming and manufacturing complex shapes. Understanding of how various parameters affect build quality is necessary. Specimens were made from 316L stainless steel at 0°, 30°, 60°, and 90° angles measured from the build plate. Three tensile and four fatigue specimens at each angle were produced. Fracture morphology investigation was performed to determine the fracture mode of specimens at each build angle. Microstructural analysis was performed on one of each orientation. The average grain size of the samples was marginally influenced by the build angle orientation. Tensile …

Characterization Of High-Purity Niobium Structures Fabricated Using The Electron Beam Melting Process, Cesar Adrian Terrazas

Open Access Theses & Dissertations

Additive Manufacturing (AM) refers to the varied set of technologies utilized for the fabrication of complex 3D components from digital data in a layer-by-layer fashion. The use of these technologies promises to revolutionize the manufacturing industry. The electron beam melting (EBM) process has been utilized for the fabrication of fully dense near-net-shape components from various metallic materials. This process, catalogued as a powder bed fusion technology, consists of the deposition of thin layers (50 - 120µm) of metallic powder particles which are fused by the use of a high energy electron beam and has been commercialized by Swedish company Arcam …

Fabrication Of A Nickel-Based Superalloy In Electron Beam Melting And Process Improvements Using Thermal Feedback From A Multi-Wavelength Pyrometer, Jonathan Minjares

Open Access Theses & Dissertations

The focus of this research was to fabricate parts composed of a nickel-based superalloy containing high levels of aluminum and titanium (NSAT) by using electron beam melting (EBM) additive manufacturing (AM) technology and utilizing thermal feedback from a multi-wavelength pyrometer to perform process improvements leading to near defect-free parts. EBM is an AM technology that utilizes metal powder to fabricate parts in layer-by-layer manner. A multi-wavelength pyrometer was implemented in an Arcam S12 (Arcam AB, Sweden) EBM system to observe and record surface temperatures throughout fabrication. Temperature data from the EBM system and the multi-wavelength pyrometer were graphed using MATLAB …

Process Study And Control Of Electron Beam Melting Technology Using Infrared Thermography, Jorge Mireles

Open Access Theses & Dissertations

An IR camera was installed in an Arcam A2 system (Arcam AB, Mölndal, Sweeden) and layer-by-layer image acquisition was achieved. The camera's capability to detect manufacturing defects was evaluated by implementing computer vision techniques using LabVIEW measurement and programming software (National Instruments, Austin, TX). Thermal maps acquired by the IR camera allowed layer-by-layer part temperature to be recorded. A core objective of this research was to study the impact of processing temperature on EBM-fabricated Ti-6Al-4V parts and achieve controlled mechanical properties. In this research, build variations were achieved by modifying parameters that change processing temperature from the standard processing temperature. …

Comparative Characterization Of Ni-Base Superalloys Fabricated By Laser And Electron Beam Melting Technologies, Krista Amato

Open Access Theses & Dissertations

Nickel-base superalloys have been used in cast and wrought, and powder metallurgy forms for nearly four decades for industrial and automotive applications. One drawback of cast alloys is that upon solidification, there is minimal microstructural control. Another issue to be improved is to eliminate the limitations of shapes and forms of fabricated alloys.

Rapid prototyping is a new technology of additive manufacturing that shows to be promising for the freeform fabrication of novel superalloys, including nickel-base alloys. New rapid manufacturing technologies allow us to produce parts in any shape that can be designed by computer-aided design (CAD) software. Additionally, the …

Additive Layer Manufacturing Of Ti-6al-4v By Electron Beam Melting From Powder Particles: Solid, Mesh And Foam Components Study, Sara M. Gaytan

Open Access Theses & Dissertations

Additive Manufacturing by Electron Beam Melting Rapid Manufacturing is a technology that consists of the fabrication of a CAD design by melting powder particles in a layer by layer fashion. In this study, Ti-6Al-4V has been utilized to fabricate solid, mesh and foam components by EBM technologies. Powder analysis of Ti-6Al-4V was performed to obtain a better understanding of the porosity obtained by the system. After proper optimization of the machine, and porosity control, microstructural analysis was performed to the components already mentioned and correlated by transmission electron microscopy. Besides the microstructural analysis, tensile and hardness testing was performed to …